Read this manual carefully. It contains important safety information.
Adult supervision is required at all times.
Operation is prohibited for anyone under age 10.
OUTLAW 110
SPORTSMAN 110
Pantone 419C
Owner's Manual for Maintenance and Safety
2019
WARNING
Operating, servicing, and maintaining a passenger vehicle or off-road vehicle can
expose you to chemicals including engine exhaust, carbon monoxide, phthalates,
and lead, which are known to the State of California to cause cancer and birth
defects or other reproductive harm. To minimize exposure, avoid breathing exhaust,
do not idle the engine expect as necessary, service your vehicle in a well-ventilated
area and wear gloves or wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
!
WARNING
Read, understand, and follow all of the instructions and safety
precautions in this manual and on all product labels.
Failure to follow the safety precautions
could result in serious injury or death.
!
A card containing important ATV safety information should be attached to
the owner's manual on the next page. If you cannot locate this card, or if it
has been removed, please call 1-800-342-3764 for assistance.
2019 Owner’s Manual
Outlaw 110
Sportsman 110
IMPORTANT SAFETY INFORMATION
Scan this QR code with your smartphone to see an important Safety Video
regarding your Polaris vehicle.
This safety video can also be found at
http://www.polaris.com/en-us/rider-support/safety. If you are on the homepage
of the Polaris website, click on the Rider Community heading and select
“Product Safety and Training Information” from the dropdown menu to access
this page.
POLARIS®, ACE™, OUTLAW®, and SPORTSMAN® are trademarks of POLARIS Industries Inc.
Copyright 2018 Polaris Industries Inc. All information contained within this publication is based on the
latest product information at the time of publication. Due to constant improvements in the design and
quality of production components, some minor discrepancies may result between the actual vehicle
and the information presented in this publication. Depictions and/or procedures in this publication are
intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as translations of
the original instructions.
Printed in U.S.A.
9929071
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Young Riders Section . . . . . . . . . . . . . . . . . . . . . . . 49
Features and Controls . . . . . . . . . . . . . . . . . . . . . . . 65
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Emission Control Systems . . . . . . . . . . . . . . . . . . . . . 99
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 171
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . 193
5
6
MESSAGES
DEAR PARENTS:
We believe your children should have the opportunity to enjoy the POLARIS riding experience along
with you. We've provided this owner’s manual to assist you and your children in learning about safe
operation and care of your new ATV.
A POLARIS ATV is not a toy and can be hazardous to operate. Make sure any child who will operate
the ATV takes a training course before operating the ATV. Make sure all operators understand and
follow all of the instructions and warnings contained in this owner’s manual.
Never allow a child under the age of 16 to operate an ATV without adult supervision. Children differ in
skills, physical abilities and judgement. Some children may not be able to operate an ATV safely. Permit
continued use only if you determine that your child has the ability and maturity to operate the ATV
safely.
For your child’s safety, be sure your child can reach and operate all ATV controls, including handlebars,
brake levers, throttle lever and engine stop switch.
The preventive maintenance program outlined in this manual is designed to ensure that all critical
components on your child’s ATV are thoroughly inspected at specific intervals. Follow all of the
instructions and recommendations in this manual.
7
MESSAGES
DEAR YOUNG OPERATORS:
Before you ride your new POLARIS ATV, there are some important things that you need to know. You
must learn how to keep yourself and those around you safe while you’re riding. Your parents and
Polaris want you to enjoy riding your new ATV, and that's why you need to read and understand the
information in your owner’s manual. You must also take an ATV training course before you begin riding.
Ask your parents to explain anything you don’t understand, and pay close attention to the warnings and
instructions you read. Your safety and the safety of others is the most important thing to think about at
all times. Never drive your ATV alone. Always make sure an adult is watching you when you ride.
Drive safely and enjoy riding your new POLARIS ATV!
9
MESSAGES
10
INTRODUCTION
The following signal words and symbols appear throughout this manual and on your vehicle. Your
safety is involved when these words and symbols are used. Become familiar with their meanings before
reading the manual.
DANGER
DANGER indicates a hazardous situation that, if not avoided, will result in death to the operator,
bystanders or person(s) inspecting or servicing the vehicle.
WARNING
WARNING indicates a hazardous situation that, if not avoided, may result in death to the operator,
bystanders or person(s) inspecting or servicing the vehicle.
11
INTRODUCTION
CAUTION
CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and inspection of components.
The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.
12
INTRODUCTION
The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a
hazard.
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle's identification numbers and key
number in the spaces provided. Remove the spare key
and store it in a safe place. An ignition key can be
duplicated only by ordering a POLARIS key blank (using
your key number) and mating it with one of your existing
keys. The ignition switch must be replaced if all keys are
lost.
q
Vehicle Identification Number (VIN)
w
Engine Serial Number
13
INTRODUCTION
WARNING
Failure to follow the warnings and safety precautions contained in this manual can result in severe
injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles
differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take
proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures
before operating a POLARIS ATV. Keep this manual with the ATV.
• Never operate an ATV without proper instruction. Take a training course.
• For your child’s safety, be sure your child can reach and operate all ATV controls, including
handlebars, brake levers, throttle lever and engine stop switch.
• Always follow the age guidelines for your vehicle. Y-10+ models are designed for children not less
than 10 years of age and Y- 6+ models are designed for children not less than 6 years of age. No
child under the age of 16 should ride any ATV designed and sold for an adult.
• Never permit a guest to operate the ATV unless the guest has read this manual and all product
labels and has completed a certified safety training course.
15
INTRODUCTION
16
SAFETY
SAFETY WARNINGS
WARNING
Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover,
which may result in serious injury or death. Heed all safety warnings outlined in this section of the
owner’s manual and in the safety DVD provided with your vehicle.
Be sure to read all of the following warnings about driving hazards and how to avoid them. These
warnings are provided for your child's safety. Be sure to explain to your young driver that the hazards
outlined in this section of this owner’s manual MUST be avoided at all times. See the OPERATION
section of this owner’s manual for proper operating procedures.
FOR MORE INFORMATION ABOUT SAFETYcall POLARIS at 1–800–342–3764.
17
SAFETY
OPERATING WITHOUT
INSTRUCTION
Operating this vehicle without
proper instruction increases
the risk of an accident. The
operator and the supervising
adult must understand how to
operate the vehicle properly
in different situations and on
different types of terrain.
All operators must read and
understand this owner’s
manual and all warning and
instruction labels before
operating the vehicle. Never
allow a guest to operate this
vehicle until the guest has
read this manual and all
product labels.
AGE RESTRICTIONS
This vehicle is for
recreational use by young
operators under adult
supervision ONLY.
Operation is prohibited for
anyone under age 10. Never
operate with a passenger
under age 10. All riders must
be able to sit with backs
against the seat, both feet flat
on the floor and both hands
on the steering wheel (if
driving) or on a passenger
hand hold.
18
SAFETY
HANDLING GASOLINE
Gasoline is highly flammable and explosive
under certain conditions.
• Never allow a child to refuel or handle
gasoline.
• Always exercise extreme caution whenever
handling gasoline.
• Always refuel with the engine stopped, and
outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks
in or near the area where refueling is
performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank
neck.
• If gasoline spills on your skin or clothing,
immediately wash it off with soap and water
and change clothing.
EXPOSURE TO EXHAUST
Engine exhaust fumes are poisonous and can
cause loss of consciousness or death in a short
time. Never start the engine or let it run in an
enclosed area.
The engine exhaust from this product contains
chemicals known to cause cancer, birth defects
or other reproductive harm. Operate this vehicle
only outdoors or in well-ventilated areas.
19
SAFETY
FAILURE TO INSPECT BEFORE
OPERATING
Failure to inspect and verify
that the vehicle is in safe
operating condition before
operating increases the risk
of an accident.
Always inspect the vehicle
before each use to make sure
it's in safe operating
condition.
Always follow the inspection
and maintenance procedures
and schedules described in
this owner’s manual.
PROTECTIVE APPAREL
Operating this ATV without
wearing an approved helmet
increases the risk of a
serious head injury in the
event of an accident.
Operating without eye
protection could result in an
accident and could increase
the chance of a serious
injury in the event of an
accident. Always wear an
approved helmet that fits
properly.
Always wear eye protection
(goggles or face shield),
gloves, boots, a long-
sleeved shirt or jacket and
long pants.
20
SAFETY
USING ALCOHOL OR DRUGS
Riding in this vehicle after
consuming alcohol or drugs
could adversely affect
operator judgment, reaction
time, balance and perception.
Never consume alcohol or
drugs before or while
operating or riding in this
vehicle.
CARRYING A PASSENGER
Carrying a passenger greatly
reduces the operator's ability
to balance and control the
ATV, which may result in an
accident or overturn. Never
carry a passenger on this
ATV.
OPERATING ON PAVEMENT
Operating an ATV on paved
surfaces (including
sidewalks, paths, parking
lots and driveways) may
adversely affect the handling
of the ATV and could result
in loss of control and
accident or overturn. Avoid
operating the ATV on
pavement. ATV tires are
designed for off-road use. If
it’s unavoidable, travel
slowly and avoid sudden
turns or stops.
21
SAFETY
OPERATING ON PUBLIC ROADS
Operating this ATV on public
streets, roads or highways
could result in a collision with
another vehicle. Never
operate the ATV on any
public street, road or
highway, including dirt and
gravel roads. In many states
it’s unlawful to operate ATVs
on public streets, roads and
highways.
OPERATING AT EXCESSIVE
SPEEDS
Operating the ATV at
excessive speeds increases
the operator's risk of losing
control. Always operate at a
speed that’s appropriate for
the terrain, the visibility and
operating conditions, and
your experience.
22
SAFETY
TURNING IMPROPERLY
Turning improperly could cause loss of traction,
loss of control, accident or rollover. Always follow
proper procedures for turning as described in this
owner’s manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
PHYSICAL CONTROL OF THE
ATV
Removing a hand from the
handlebars or feet from the
footrests during operation
can reduce your ability to
control the vehicle or cause
loss of balance and ejection
from the ATV. If the
operator’s foot is not firmly
planted on the footrest, it
could also contact the rear
wheels.
Never remove your hands
from the handlebars while
operating, and always keep
both feet on the footrests.
23
SAFETY
JUMPS AND STUNTS
Attempting wheelies, jumps
and other stunts increases
the risk of an accident or
overturn. Never attempt
wheelies, jumps, or other
stunts. Avoid exhibition
driving.
DESCENDING HILLS
IMPROPERLY
Improperly descending a hill could cause loss of
control or overturn.
• Always follow proper procedures for traveling
down hills as described in the owner’s manual.
NOTE
A special technique is required when braking
while traveling downhill. See page 90.
• Always check the terrain carefully before
descending a hill.
• Shift your weight rearward.
• Never travel down a hill at high speed.
• Avoid traveling down a hill at an angle, which
would cause the vehicle to lean sharply to one
side. Travel straight down the hill when
possible.
24
SAFETY
IMPROPER HILL CLIMBING
Improper hill climbing could
cause loss of control or
overturn. Always follow
proper procedures for
climbing hills as described in
the owner’s manual. See
page 25.
OPERATING ON STEEP HILLS
Operating on excessively steep hills could cause
an overturn. Never operate on hills too steep for
the ATV or for your abilities. Never operate the
ATV on hills steeper than 15 degrees.
25
SAFETY
CROSSING HILLSIDES
Driving on a sidehill is not
recommended. Improper
procedure could cause loss
of control or overturn. Avoid
crossing the side of any hill
unless absolutely necessary.
If crossing a hillside is
unavoidable, always follow
proper procedures as
described in the owner’s
manual. See page 89.
Never attempt to turn the
ATV around on any hill until
you’ve mastered the turning
technique (on level ground)
as described in the owner’s
manual. See the Turning
Around on a Hill section for
details.
STALLING WHILE CLIMBING A
HILL
Stalling, rolling backwards or
improperly dismounting
while climbing a hill could
cause an overturn.
Always maintain a steady
speed when climbing a hill.
If you lose all forward speed:
Keep your weight uphill.
Apply the front brakes
gradually (right lever). When
fully stopped, apply the rear
brake as well (left lever) and
then lock the parking brake.
If the ATV begins rolling
downhill:
26
SAFETY
Keep weight uphill. Never
apply engine power. Never
apply the rear brake while
rolling backwards. Apply the
front brake slowly. When
fully stopped, apply rear
brake as well, and then lock
the parking brake. Dismount
on uphill side, or to either
side if pointed straight uphill.
Turn the ATV around and
remount, following the
procedure described in the
Owner’s Manual. See the
Turning Around on a Hill
section for details.
OPERATING IN UNFAMILIAR
TERRAIN
Failure to use extra caution
when operating on unfamiliar
terrain could result in an
accident or overturn.
Unfamiliar terrain may
contain hidden rocks,
bumps, or holes that could
cause loss of control or
overturn.
Travel slowly and use extra
caution when operating on
unfamiliar terrain. Always be
alert to changing terrain
conditions.
27
SAFETY
OPERATING ON SLIPPERY
TERRAIN
Failure to use extra caution
when operating on
excessively rough, slippery
or loose terrain could cause
loss of traction, loss of
control, accident or overturn.
Do not operate on
excessively rough, slippery
or loose terrain until you’ve
learned and practiced the
skills necessary to control
the ATV on such terrain.
Always use extra caution on
rough, slippery or loose
terrain.
OPERATING IMPROPERLY IN
REVERSE
Improperly operating in reverse could result in a
collision with an obstacle or person. Always
follow proper operating procedures as outlined in
this manual.
Before shifting into reverse gear, always check
for obstacles or people behind the vehicle. When
it's safe to proceed, back slowly.
28
SAFETY
IMPROPER VEHICLE
MODIFICATIONS
Improper installation of accessories or
modification of the ATV may cause changes in
handling, which could cause loss of control or an
accident.
Never modify the ATV through improper
installation or use of accessories. All parts and
accessories added to the vehicle must be
genuine POLARIS Industries Inc. or equivalent
components designed for use on this ATV and
should be installed and used according to
approved instructions. An authorized dealer can
assist.
OPERATING OVER OBSTACLES
Improperly operating over obstacles could cause
loss of control or overturn.
Before operating in a new area, check for
obstacles. Avoid operating over large obstacles
such as rocks and fallen trees. If unavoidable,
use extreme caution and always follow proper
operating procedures as outlined in this manual.
29
SAFETY
SKIDDING OR SLIDING
Skidding or sliding can cause loss of control or
overturn (if tires regain traction unexpectedly).
On slippery surfaces such as ice, travel slowly
and use extra caution to reduce the chance of
skidding or sliding.
IMPROPER TIRES AND
MAINTENANCE
Operating this vehicle with improper tires or with
improper or uneven tire pressure could cause
loss of control, accident or rollover.
Always use the size and type of tires specified for
your vehicle. Always maintain proper tire
pressure as described in this owner's manual
and on safety labels.
OPERATING ON FROZEN BODIES
OF WATER
Operating on frozen bodies of water may result in
serious injury or death if the ATV and/or the
operator fall through the ice. Never operate the
ATV on a frozen body of water.
OPERATING THROUGH DEEP
WATER
Operating the ATV through deep or fast-flowing
water could cause the tires to float, causing loss
of control or overturn.
Avoid operating the ATV through deep or fast-
flowing water. If it's unavoidable to enter water
that exceeds the recommended maximum depth
(see the Driving Through Water section for
details):
• Travel slowly.
30
SAFETY
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion.
Do not make sudden turns or stops, and do
not make sudden throttle changes.
• Wet brakes may have reduced stopping ability.
After leaving water, test the brakes. Apply
them lightly several times while driving. The
friction will help dry out the pads.
IMPROPER CARGO LOADING
Overloading the ATV or
carrying/towing cargo may
cause changes in handling,
which could cause loss of
control or an accident.
Never haul cargo or tow a
load with this ATV. Never tow
or pull an object behind the
ATV. A wagon, sled or other
towed object does not have
brakes or steering. The
object may overturn or
collide with other objects.
Never exceed the stated
load capacity for this ATV.
31
SAFETY
OPERATING A DAMAGED ATV
Operating a damaged ATV can result in an
accident. After any overturn or accident, have a
qualified service dealer inspect the entire
machine for possible damage, including (but not
limited to) brakes, throttle and steering systems.
UNAUTHORIZED USE OF THE ATV
Leaving the keys in the ignition can lead to
unauthorized use of the vehicle, which could
result in an accident or overturn. Always remove
the ignition key when the vehicle is not in use.
PHYSICAL SKILLS
Safe operation of this rider-active vehicle
requires good judgement and physical skills.
Persons with cognitive or physical disabilities
who operate this vehicle have an increased risk
of overturn and loss of control.
HOT EXHAUST SYSTEMS
WARNING
Exhaust system components are very hot during
and after use of the vehicle. Hot components can
cause burns and fire. Do not touch hot exhaust
system components. Always keep combustible
materials away from the exhaust system.
Use caution when traveling through tall grass,
especially dry grass. Always inspect the
underside of the vehicle and areas near the
exhaust system after driving through tall grass,
weeds, brush and other tall ground cover.
Promptly remove any grass or debris clinging to
the vehicle.
32
SAFETY
SAFETY TRAINING
ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family
members who will be riding the ATV to take a training course.
If you purchased a new POLARIS ATV in the United States, your dealer provided information about the
authorized ATV RiderCourse℠ that is available to you and your eligible family members. This training is
included in the purchase price of your ATV.
In addition, you were provided with printed material and a video or DVD that instructs operators on safe
operating procedures. You should review this information with your child on a regular basis. Do not
allow other children to ride this ATV unless they have read the manual, seen the instructional video or
DVD and taken and completed an approved ATV safety training course.
If you purchased a used POLARIS ATV in the United States, you can enroll in the ATV RiderCourse℠
for a fee. Call ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.
If you purchased a POLARIS ATV outside the United States, please contact your dealer or local law
enforcement agencies for information about safety training.
FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Consumer Product
Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
POLARIS at 1-800-342-3764.
33
SAFETY
EQUIPMENT MODIFICATIONS
Your POLARIS vehicle is designed to provide safe operation when used as directed.
WARNING
Modifying this vehicle in any way can change the top speed, stability and handling performance of this
vehicle. Modifications that increase speed, decrease stability or change performance may present a
greater risk to inexperienced or younger operators and could result in loss of control and serious injury
or death. Use only POLARIS-approved accessories to modify this vehicle. Review all vehicle changes
with your child prior to operating.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-POLARIS-
approved equipment and/or modifications have been added to the vehicle that increase speed or
power.
34
SAFETY
EUROPEAN VIBRATION AND NOISE
The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is
measured per EN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as indicated by the test
procedure(s).
The uncertainty of vibration exposure measurement is dependent on many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
35
SAFETY
EYE PROTECTION
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle,
always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends
wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8,
Z87.1, or CE. Make sure protective eye wear is kept clean.
HELMET
Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always
wear a helmet that meets or exceeds established safety standards. Parents should verify that the
provided helmets fit properly. If a helmet doesn't fit, parents should obtain one in the proper size.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a
circle surrounding the letter E, followed by the distinguishing number of the country which has granted
approval. The approval number and serial number will also be displayed on the label.
37
SAFETY
GLOVES
Wear gloves for comfort and for protection from sun, cold weather and other elements.
BOOTS
Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare
feet or sandals.
CLOTHING
Wear long sleeves and long pants to protect arms and legs.
RIDER COMFORT
Under certain operating conditions, heat generated by the engine and exhaust system can elevate
temperatures in the driver and passenger cab area. The condition occurs most frequently when a
vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an
extended period of time. The use of certain windshield, roof and/or cab systems may contribute to this
condition by restricting airflow. Any discomfort due to heat buildup in this area can be minimized by
wearing proper riding apparel and by varying speeds to increase airflow.
38
SAFETY
SAFETY LABELS AND LOCATIONS
Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of
the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on
your vehicle, always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to
purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part
number is printed on the label.
39
SAFETY
OPERATION WARNING
q
WARNING
Improper ATV use can result in SEVERE INJURY OR
DEATH.Always use an approved helmet and protective gear.
Never use on public roads. Never carry passengers. Never
use with drugs or alcohol.NEVER operate: without proper
training or instruction; at speeds too fast for your skills or the
conditions; on public roads - a collision can occur with another
vehicle; with a passenger - passengers affect balance and
steering and increase risk of losing control. ALWAYS: use
proper riding techniques to avoid vehicle overturns on hills
and rough terrain and in turns; avoid paved surfaces -
pavement may seriously affect handling and control. LOCATE
AND READ OWNER’S MANUAL. FOLLOW ALL
INSTRUCTIONS AND WARNINGS.
41
SAFETY
DISCRETIONARY WARNING
q
WARNING
Never operate this ATV on HILLS steeper than 15
degrees 15°. To prevent overturn on hilly terrain, use
throttle and brakes gradually and shift weight uphill.
REVERSE operation can be dangerous even at low
speeds. Steering becomes difficult. To prevent loss of
control, avoid sudden braking or sharp turns.
42
SAFETY
CLUTCH COVER WARNING
q
WARNING
• Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard removed.
• Do not touch clutch cover, cover may become hot.
• Do not modify engine or clutch. Doing so can cause
part failure, possible imbalance, and excessive
engine RPM which can result in serious injury or
death.
47
SAFETY
48
YOUNG RIDERS SECTION
KNOW YOUR ATV
PARENTS: POLARIS Youth ATVs are equipped with a speed control system to allow adults to limit the
speed of the vehicle for the rider's skill and experience. More information on speed limiting functions
can be found beginning on page 126. These units are not designed for adult use. Serious damage to
the vehicle may occur if the maximum rider weight capacity is exceeded. See the specifications section
beginning on page 159 for your ATV’s capacity.
YOUNG RIDERS: Before you ride your new POLARIS ATV, there are some important things that you
need to know. Your safety and the safety of others is the most important thing to think about at all times.
As the driver of the ATV, you must learn how to keep yourself and those around you safe while you’re
riding.
49
YOUNG RIDERS SECTION
WARNING
This is the safety alert symbol. When you see this symbol on your ATV or in this manual it means PAY
ATTENTION because you could die or be seriously injured if you don’t follow the instructions.
Before you have an adult start the engine for you for the first time, let's learn about the controls on your
new ATV.
1. Engine Stop Switch
q
- When the engine is running, push this button down to shut the engine off
quickly. The button must be up before you can start the engine again.
2. Horn Button
w
- Press the horn button to sound the horn.
50
YOUNG RIDERS SECTION
6. Seat Latch
y
- The seat latch is under the left edge of the seat. Reach under the left rear fender
and pull back on the latch to remove the seat. To replace the seat, set it in place and push down on
the seat above the latch. Always make sure the seat is locked in place before riding.
54
YOUNG RIDERS SECTION
7. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the ATV. The
left lever controls the rear brake
u
. The right lever controls the front brake
o
. Always squeeze both
brake levers at the same time.
WARNING
Always squeeze both brake levers at the same time or you could lose control of the ATV and be
seriously injured. Always take your thumb off the throttle lever when you squeeze the brake levers.
55
YOUNG RIDERS SECTION
10.Tether Strap and Switch - The tether strap must always be attached snugly to your right wrist and
to your ATV every time you drive. If you fall off your ATV, the tether strap will pull away from the
switch and the engine will stop.
Outlaw
Ignition Switch
a
Tether Switch
s
Sportsman
Ignition Switch
d
Tether Switch
f
57
YOUNG RIDERS SECTION
WARNING
Never ride without the tether strap attached to your right wrist and to your ATV. Be careful not to let the
cord get tangled around the handlebars or any part of your body.
Let’s review the three ways to stop the engine of your ATV.
1. Push the engine stop switch down.
2. Pull the tether strap off the ATV.
3. Turn the key off.
58
YOUNG RIDERS SECTION
PRE-RIDE CHECK
We’re almost ready to have an adult start your ATV. But before the ATV is started for the first time, you
must do a Pre-Ride Check. In fact, every time you want to ride you must have an adult help you check
some things on your ATV before starting it. Let’s learn about these things now.
1. Make sure the throttle doesn’t stick. Check this by pushing the throttle lever toward the handlebar
and then letting go. The lever should come right back to where it was before you pushed it. If it
comes back slowly or stays close to the handlebar, the ATV has a sticky throttle. This means that
something is wrong or broken and must be fixed before you can ride your ATV safely.
WARNING
Never start the engine if you have a sticky throttle. You could be seriously hurt if you ride with a sticky
throttle. Have an adult or your POLARIS dealer fix the throttle before you ride.
2. Make sure the brakes don’t stick. Check the brake levers by squeezing them toward the handlebar
and then letting go. They should come right back to where they were before you squeezed. If they
go back slowly or stay close to the handlebar, your ATV has sticky brakes. They must be fixed
before you can ride your ATV safely.
59
YOUNG RIDERS SECTION
WARNING
Never start the engine if your ATV has sticky brakes. You could be seriously hurt if you ride with sticky
brakes. Have an adult or your POLARIS dealer fix the sticky brakes before you ride.
3. Have an adult check to see if your ATV needs more gas. Children must never add their own
gasoline. This must always be done by an adult. Before anyone adds gasoline to your ATV they
must read the instructions and warnings in the Safety Labels and Locations section of this manual.
WARNING
Always have an adult put gas in your ATV. Never try to do it yourself.
4. If you used the storage area under the seat, make sure the seat is locked in place.
5. Have an adult check the engine oil level when the engine is cold. The engine is very hot after it has
been running and it can burn your skin if you touch it. Children must never check the oil on their
own. An adult should always be in charge of keeping the gas and oil levels at the full marks.
60
YOUNG RIDERS SECTION
6. This last check is done with the engine running. You must check to make sure that all three ways to
stop the engine of your ATV are working the way they should. Do you remember what they are? If
you can’t remember the three ways to stop the engine, go back to page 49 and review. Then have
an adult help you start the engine. Practice stopping the engine all three ways.
RIDING RULES
Now you’re ready to learn about riding your POLARIS ATV. There are some things you can do and
there are some things you must never do. Rules are very important when you’re driving an ATV. Adults
have riding rules, too. The rules help keep us safe when we ride.
NOTE
The adult with you is your teacher. Always pay attention to what your teacher says so you can learn
how to always drive safely.
WARNING
Always follow the safe riding rules found on the next pages. You or others around you could be
seriously hurt if you don’t follow the safe riding rules.
61
YOUNG RIDERS SECTION
RIDING GEAR
NOTE
Always wear the right kind of clothing and safety gear when riding your ATV.
Helmet: Your helmet is very important for safe riding. A helmet can prevent a severe head injury.
Eye Protection: Always wear shatterproof goggles or a helmet face shield, and always keep them
clean so you can see where you’re driving.
Gloves: Wear gloves to protect your hands from sun and wind. Gloves will also protect your hands
from scrapes and scratches.
Boots: Wear sturdy over-the-ankle boots to keep your feet dry. Boots will also protect your feet and
ankles from scrapes and scratches.
Clothing: Make sure your clothing fits properly. If it’s too small, it could keep you from moving easily
when you shift your weight. If it’s too big, it could hang down and get caught in a moving part. Wear long
sleeves and long pants to protect your arms and legs.
62
YOUNG RIDERS SECTION
RULES TO REMEMBER
• Always attach the tether strap to your right wrist and to the ATV before riding.
• Make sure you know where you’re going to drive before your ATV is started. Make sure the area is
safe all around your ATV.
• Your ATV is made for one person. Never carry a passenger. A passenger will make the ATV harder
to drive. You may lose control and hurt yourself and your passenger.
• Always drive your ATV while sitting down. Keep both hands on the handlebars and keep both feet on
the footrests.
• Always be alert and pay attention to where you’re driving. Pay attention to other drivers, and be even
more careful around them because you don’t know what they’re going to do.
• Never follow another ATV too closely. You need lots of time and space to stop your ATV.
• Never tow or pull an object behind the ATV.
• Never ride without supervision. An adult should always be watching you in case you need help.
Always drive within the sight of an adult.
• Never ride on public trails.
• Don’t ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from
hearing cars, trucks or trains that may be coming towards you.
• Don’t ride at night. Your ATV doesn’t have lights that are safe for driving in the dark.
63
YOUNG RIDERS SECTION
• Learn where there are lakes, rivers, ponds and ditches in your driving area. Stay away from them.
• Never ride on frozen water. You could get hurt or you could even die. All ice can be dangerous!
• Ride your ATV only where you know it is safe to drive and where you have permission to drive. Be
careful of the things around you.
• Always be a polite driver. (Don’t drive through the flower garden or over the little trees you planted!).
• Always do your best to help take care of nature.
Respect your ATV.
Respect your environment.
You will earn the respect of everyone.
Enjoy riding your new POLARIS ATV!
64
YOUNG RIDERS SECTION
FEATURES AND CONTROLS
SWITCHES / BUTTONS
MAIN KEY SWITCH
Turn the key clockwise to the ON position before starting the engine. To avoid draining the battery,
always turn the key to the OFF position when the engine is not running. Always remove the ignition key
when the vehicle is not in use.
ENGINE STOP SWITCH
The engine will not start or run when the stop switch
q
is down, in the OFF position. Its purpose is to provide
the operator with a quick means of engine shutdown in
case of stuck throttle or other emergency.
Both the main switch and the engine stop switch shut
off all electrical power to the entire vehicle. To stop the
engine quickly, push the stop switch down.
65
FEATURES AND CONTROLS
THROTTLE CONTROLS
WARNING
Operating an ATV with sticking or improperly operating throttle controls could cause an accident and
lead to severe injury or death.
Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your
dealer or other qualified person for service if throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result in an accident if the
throttle lever sticks during operation. Always check the lever for free movement and return before
starting the engine. Also check occasionally during operation.
The throttle release switch limits engine speed in the event of a throttle system malfunction.
Modifications to the throttle release switch could result in failure to perform as designed, which could
result in an accident. Do not attempt to modify the throttle control system or replace it with any after
market throttle mechanism. Always ensure that the throttle cable is installed and properly routed to
the throttle control.
67
FEATURES AND CONTROLS
THROTTLE LEVER
Press the throttle lever
q
toward the handlebar to increase
engine speed and vehicle movement. Engine speed returns
to idle when the lever is released.
This ATV is equipped with a throttle release switch, which is
designed to reduce the risk of a frozen or stuck throttle. If the
throttle cable should stick in an open position when the
operator releases the throttle lever, engine speed will be
limited to idle speed.
NOTE
Idle RPM is preset by the manufacturer. If the engine idle
speed is not satisfactory, please see your POLARIS dealer
or other qualified service facility for adjustment.
68
FEATURES AND CONTROLS
SHIFT LEVER
To change gears, stop the ATV. With the engine idling, move the lever to the desired gear. Do not try to
shift gears with engine speed above idle or while the ATV is moving.
Maintaining shift linkage adjustment is important to assure proper transmission function. See your
dealer or other qualified person if you experience any shifting problems.
SHIFT PATTERN
F: Forward Gear
N: Neutral
R: Reverse
NOTICE
Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission
could result. Always shift when the vehicle is stationary and the engine is at idle.
69
FEATURES AND CONTROLS
BRAKES
Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever
controls the rear brakes
q
. The right lever controls the front brakes
w
.
WARNING
Applying only one brake could cause loss of control and result in serious injury or death. Always apply
both brakes at the same time.
70
FEATURES AND CONTROLS
PARKING BRAKE
1. Squeeze the left brake lever.
2. Push the parking brake lock
q
down to lock the brake
lever in place.
3. Release the brake lever.
4. To release the parking brake lock, squeeze and release
the brake lever. The parking brake will release
automatically.
5. Always lock the parking brake whenever the vehicle is left
unattended.
WARNING
Operating the ATV while the parking brake is engaged could cause an accident resulting in serious
injury or death. It could also result in driveline or engine damage. Always be sure to disengage the
parking brake before operating the ATV.
72
FEATURES AND CONTROLS
INDICATOR LIGHTS
POLARIS Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not
operate this ATV after dark. Use caution and drive at reduced speeds in conditions of reduced visibility.
This ATV is designed for off-road use only. Do not operate this ATV on streets or highways.
Indicator
Description
Neutral
q
Transmission is in neutral.
Reverse
w
Transmission is in reverse.
Low Fuel
e
The ATV can operate 7-10 miles (11-16 km) before the tank is completely
empty.
Check Engine
r
A flashing light indicates an overheated engine. The system will automatically
reduce engine power. A solid light indicates an EFI-related fault has occurred.
Do not operate the ATV. Serious engine damage could result. Your POLARIS
dealer can assist.
73
FEATURES AND CONTROLS
FUEL SYSTEM
Gas Cap
The fuel tank filler cap
q
is located directly below the
handlebars.
Use unleaded gasoline with a minimum pump octane
number of 87=(R+ M/2) octane. Non-ethanol fuel is
recommended.
Do not use fuel with ethanol content greater than 10
percent, such as E-85 fuel.
Refer to the Specifications chapter for fuel tank
capacity.
75
FEATURES AND CONTROLS
76
OPERATION
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover,
which may result in serious injury or death. Read and understand all safety warnings outlined in the
safety section of this owner’s manual.
VEHICLE BREAK-IN PERIOD
The break-in period for your new POLARIS vehicle is defined as the first ten hours of operation, or the
time it takes to use the first two full tanks of gasoline.
No single action on your part is as important as a proper break-in period. Careful treatment of a new
engine and drive components will result in more efficient performance and longer life for these
components. Perform the following procedures carefully.
77
OPERATION
NOTICE
Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts
and drive components. Do not operate at full throttle or high speeds during the first three hours of use.
Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the
recommended oil. Never substitute or mix oil brands.
1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Never
allow a child to handle gasoline.
2. Check the oil level. See page 113. Add the recommended oil as needed to maintain the oil level in
the safe operating range.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with operation and
handling.
4. Vary throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection
checklist. See page 80.
6. Perform the following maintenance at 10 hours or one month.
78
OPERATION
Item
At 10 Hours or One Month
(End of Break-In Period)
Ref.
Engine Oil Change Perform break-in oil change page 114
Oil Pre-filter Screen Clean filter with oil change page 114
Transmission Oil Perform break-in oil change page 116
Drive Chain Adjust and lubricate page 135
Valve Clearance See your dealer or other qualified
person for inspection and adjustment
-
79
OPERATION
PRE-RIDE INSPECTION
CAUTION
Failure to inspect and verify that the vehicle is in safe operating condition before operating increases
the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating
condition.
ITEM REMARKS PAGE
Brake system/lever travel Ensure proper operation page 128
Front suspension Inspect, lubricate if necessary page 109
Rear suspension Inspect, lubricate if necessary page 109
Steering Ensure free operation, lubricate if necessary page 134
Tires Inspect condition and pressure page 39
page 142
80
OPERATION
ITEM REMARKS PAGE
Wheels/fasteners Inspect, ensure fastener tightness; check that
axle nuts are secured by cotter pins
page 142
Frame nuts, bolts, fasteners Inspect, ensure tightness
-
Fuel and oil Ensure proper levels page 39
page 75
Grass and debris Remove grass and debris from the vehicle,
especially on the underside and near the
exhaust system
-
Throttle Ensure proper operation page 59
page 67
Engine Stop Switch Ensure proper operation page 65
Air filter, pre-filter Inspect and clean, or replace page 138
81
OPERATION
ITEM REMARKS PAGE
Daytime running lights Ensure proper operation page 144
Brake light Ensure proper operation page 144
Drive Chain Check condition and slack; refer to drive chain
adjustment
page 135
Loose or Damaged components Visually inspect for any damaged components
or loose fasteners
-
Riding Gear Wear helmet, goggles, protective clothing page 36
SAFE OPERATION PRACTICES
1. Complete the recommended safety training before operating this vehicle. See page 33.
2. Do not allow anyone under age 10 to operate the vehicle.
3. Never carry a passenger on this ATV.
82
OPERATION
4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. Never
allow a child to handle gasoline.
5. Never exceed the maximum weight capacity of the vehicle. When determining the weight you are
adding to the vehicle, include the weight of the operator, accessories and loads on the racks (if
equipped). The combined weight of these items must not exceed the maximum weight capacity.
6. Ride this vehicle only in areas permitted by a supervising adult. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt and gravel roads.
7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive
speeds. DO NOT attempt to do power slides, “donuts”, jumps or other driving stunts. Keep both
hands on the steering wheel at all times.
8. Never consume alcohol or drugs before or while operating this vehicle.
9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire
pressure.
10.Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer
inspect the entire machine for possible damage.
11. Never operate the vehicle on a frozen body of water.
83
OPERATION
12. Do not touch hot exhaust system components. Always keep combustible materials away from the
exhaust system.
13.Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.
STARTING THE ENGINE
NOTICE
Operating the vehicle immediately after starting could cause engine damage. Allow the engine to
warm up for several minutes before operating the vehicle.
1. Shift the transmission to neutral.
2. Lock the parking brake.
3. Sit on the vehicle. Attach the tether strap to the ATV and to your wrist.
4. Push the engine stop switch up to the ON position.
5. Turn the ignition key to ON.
84
OPERATION
6. Squeeze the rear brake lever and press the start button. The rear brake lever must be engaged or
the engine won’t start.
7. Do not press the throttle while starting the engine. Activate the starter for a maximum of five
seconds, releasing the button when the engine starts. If it doesn’t start, release the starter, wait five
seconds, then activate for another five seconds. Repeat until the engine starts.
STOPPING THE ENGINE
1. Release the throttle completely.
2. Apply the brakes until the vehicle stops moving.
3. Shift the transmission to neutral.
4. Stop the engine. There are three ways to stop the engine:
• Turn the key off.
• Push the engine stop switch down.
• Pull the tether strap off the ATV.
5. Lock the parking brake.
85
OPERATION
6. To avoid draining the battery, always turn the key to the OFF position when the engine is not
running.
DRIVING PROCEDURE
1. Sit upright with both feet on the footrests and both hands on the handlebars.
2. Shift the transmission to neutral.
3. Start the engine and allow it to warm up.
4. Check your surroundings and determine your path of travel.
5. Squeeze the left brake lever.
6. Shift the transmission to the desired gear.
7. Slowly release the brake lever.
8. Slowly press the throttle with your right thumb and begin driving.
9. Drive slowly at first. Practice turning and using the throttle and brakes on level surfaces.
86
OPERATION
MAKING TURNS
Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This
means that the wheel on the outside of the turn must travel a greater distance than the inside wheel
when turning and the inside tire must slip traction slightly.
To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while
supporting your weight on the outer footrest. This technique alters the balance of traction between the
rear wheels, allowing the turn to be made smoothly.
Practice making turns at slow speeds.
WARNING
Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at
high speeds.
DRIVING IN REVERSE
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
87
OPERATION
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
DRIVING UPHILL
Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could
cause loss of control or overturn. Whenever traveling uphill, follow these precautions:
1. Drive straight uphill.
2. Avoid steep hills (15° maximum).
3. Always check the terrain carefully before ascending any hill.
4. Never climb hills with excessively slippery or loose surfaces.
5. Keep both feet on the footrests.
88
OPERATION
6. Shift body weight uphill.
7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause
the ATV to flip over backwards.
8. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or
person could be on the other side of the hill.
9. Remain alert and be prepared to take emergency action. This may include quick dismounting of the
vehicle.
DRIVING ON A SIDEHILL (SIDEHILLING)
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn.
Avoid crossing the side of any hill unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Lean into the hill, transferring your upper body weight uphill while keeping your feet on the footrests.
3. If the vehicle begins to slide or tip, quickly turn the front wheel downhill, if possible, or dismount on
the uphill side immediately!
89
OPERATION
DRIVING DOWNHILL
When driving downhill, follow these precautions:
1. Avoid steep hills (15° maximum).
2. Shift body weight uphill. Transfer your weight to the rear of the vehicle.
3. Drive straight downhill.
4. Slow down. Excessive speed when traveling downhill can cause loss of control.
5. Apply the front and rear brakes at the same time, and very slightly, to aid in slowing.
TURNING AROUND ON A HILL
If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.
1. Stop the vehicle and lock the parking brake while keeping body weight uphill.
2. Shift the transmission to neutral.
3. Shut off the engine.
90
OPERATION
4. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
5. Staying uphill of the ATV, turn the handlebars full left.
6. While holding the brake, release the parking brake lock and slowly release the brake, allowing the
ATV to roll around to your right until it’s pointing across the hill or slightly downward.
7. Lock the parking brake and remount the ATV from the uphill side, keeping body weight uphill.
8. Restart the engine.
91
OPERATION
9. Squeeze the rear brake lever.
10.Shift the transmission to forward gear.
11. Release the parking brake and drive slowly, controlling speed with the rear brake, until the ATV is on
more level ground.
PARKING ON A HILL OR INCLINE
Avoid parking on a hill or incline if possible. If it’s
unavoidable, follow these precautions:
1. Stop the engine.
2. Lock the parking brake.
3. Always block the rear wheels on the downhill side as
shown in the illustration.
92
OPERATION
DRIVING ON SLIPPERY SURFACES
Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather,
follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause
skids.
4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the
skid and shifting your body weight forward.
93
OPERATION
DRIVING OVER OBSTACLES
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and
low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are
immediately visible.
4. Never attempt to operate over large obstacles, such as rocks or fallen trees.
94
OPERATION
DRIVING THROUGH WATER
Your ATV can safely operate through shallow water. The
recommended maximum depth for your ATV is below the
bottom of the footrests. Follow these precautions when
operating through water:
1. Determine water depth and current before entering water.
2. If crossing a stream, choose a crossing where both banks
have gradual inclines.
3. Avoid operating through deep or fast-flowing water.
4. After driving through water, dry the brakes by applying
light pressure to the levers (while moving) until braking
action is normal. If you do not perform this procedure,
your brakes may be ineffective.
95
OPERATION
NOTICE
Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water
deeper than the footrest level. As soon as possible, perform the inspections and maintenance
services outlined in the Periodic Maintenance Chart section. Engine oil, gearcase oil and all grease
fittings need special attention.
If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, service
is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible
to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle Immersion
section, and take the vehicle in for service at the first opportunity.
HAULING CARGO
The SPORTSMAN was designed with racks to carry small loads. Read and follow all of the instructions
for hauling cargo on the following pages.
Never carry cargo on the OUTLAW.
96
OPERATION
WARNING
Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of
control, which can result in serious injury or death. Always follow these precautions when hauling
cargo:
• Place 1/3 of the cargo weight on the front rack and 2/3 on the rear rack. Carrying loads on only one
rack increases the chance of a tipover.
• Slow down. Allow more space for stopping the ATV when hauling cargo.
• Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications
section beginning on page 159.
• Secure all cargo before driving. Loose cargo may move or shift, which could cause loss of control
or a tipover. Use suitable tie-downs or rope to secure the cargo. Do not allow cargo or tie straps to
hang over the edges of the racks.
• Carry only small loads that fit on the racks. Tall loads raise the center of gravity of the vehicle and
may cause loss of control or a tipover.
• Never allow a person to ride on the racks.
• Never tow or pull an object behind the ATV. A wagon, sled or other object towed behind an ATV
does not have brakes or steering. The object may overturn or collide with other objects and cause
serious injuries.
97
OPERATION
98
EMISSION CONTROL SYSTEMS
NOISE EMISSION CONTROL SYSTEM
Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.
A. EPA noise control requirements (40 CFR 205) and local noise level requirements.
OPERATION ON PUBLIC LANDS IN THE U.S.A.
Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS
standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the
vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are
subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.
99
EMISSION CONTROL SYSTEMS
CRANKCASE EMISSION CONTROL SYSTEM
This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the
combustion chamber by the intake system. All exhaust gases exit through the exhaust system.
EXHAUST EMISSION CONTROL SYSTEM
Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls
fuel delivery. The engine and EFI components are set at the factory for optimal performance and are
not adjustable.
The emissions label is located on the inside of the lower left frame tube (below driver’s foot area).
ELECTROMAGNETIC INTERFERENCE
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of UN ECE Regulation 10.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-
active implantable medical devices (such as heart monitoring or controlling devices) should review the
limitations of their device and the applicable electromagnetic standards and directives that apply to this
vehicle.
100
EMISSION CONTROL SYSTEMS
MAINTENANCE
PERIODIC MAINTENANCE CHART
To help you perform routine maintenance, a tool kit
q
is
provided in the storage compartment under the seat.
Maintenance intervals in the following charts are based
upon average riding conditions and an average vehicle
speed of approximately 10 miles per hour. Vehicles
subjected to severe use must be inspected and serviced
more frequently. Record maintenance and service in the
Maintenance Log beginning on page 193.
Inspect, clean, lubricate, adjust and replace parts as
necessary. When inspection reveals the need for
replacement parts, genuine POLARIS parts are available
from your POLARIS dealer. Equivalent parts may be used
for emissions-related service.
Service and adjustments are critical. If you’re not familiar
with safe service and adjustment procedures, have a
qualified dealer perform these operations.
101
MAINTENANCE
SEVERE USE DEFINITION
• Frequent immersion in mud, water or sand
• Frequent or prolonged operation in dusty environments
• Short trip cold weather operation
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants
collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the cause. Your dealer can assist.
MAINTENANCE CHART KEY
SYMBOL DESCRIPTION
▶ Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized Polaris dealer or other qualified person perform these services.
102
MAINTENANCE
WARNING
Improperly performing the procedures marked with a D could result in component failure and lead to
serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these
services.
Perform all services at whichever maintenance interval is reached first. Record maintenance and
service in the Maintenance Log.
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOURS CALENDAR
MILES
(KM)
Steering
Daily
Check each day before driving the vehicle. Make
adjustments as needed. See the Pre-Ride Checklist.
Front Suspension
Rear Suspension
Tires
Brake Lever Travel
Brake System
103
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOURS CALENDAR
MILES
(KM)
Wheels / Fasteners
Frame Fasteners
Engine Oil Level
Air Filter, pre-filter,
& main element
-
Daily
-
Inspect; clean often; replace as needed
Air box sediment
tube
-
Daily
-
Drain deposits when visible
Daytime running
lights/taillight
-
Daily
-
Check operation; apply dielectric grease if replacing
Drive Chain -
Daily
-
Inspect daily, adjust as needed, check often if driving in
wet conditions.
CVT Housing (if
equipped)
-
Weekly
-
Drain water as needed, check often if driving in wet
conditions.
Break-in
Maintenance
After first 10 hours of operation
Perform break-in maintenance
104
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOURS CALENDAR
MILES
(KM)
▶
D
Brake lever travel /
brake freeplay
10
Monthly
100
(160)
Inspect periodically
Spark Plug
10
Monthly
100
(160)
Clean; check condition; adjust gap; replace as needed
Fuel System
20
Monthly
-
Inspect; cycle key to pressurize fuel pump; check lines
and fittings for leaks and abrasion
Battery
20
Monthly
200
(320)
Check terminals; clean; test
▶
Engine Oil Change
30 6 M
300
(480)
Change the oil and filter
▶ Transmission oil 40 12 M
400
(640)
Drain and change the oil
▶
Oil pre-filter screen
40 12 M
400
(640)
Clean filter at every oil change; clean annually if ATV is
operated less than 10 hours
▶ General Lubrication 50 3 M
500
(800)
Lubricate all fittings, pivots, cables, etc.
105
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOURS CALENDAR
MILES
(KM)
D Valve clearance 50 3 M
500
(800)
Check clearance; see your dealer for adjustments
D
Throttle cable/
release Switch
50 6 M
500
(800)
Inspect, adjust, lubricate; replace if necessary
Throttle body intake
duct
50 6 M
500
(800)
Inspect duct for proper sealing/air leaks
D Drive belt 50 6 M
500
(800)
See your POLARIS dealer
▶D
Brake pad wear
50 6 M
500
(800)
See your POLARIS dealer
D
Fuel System/Filter
100 12 M
600
(1000)
Cycle key to pressurize fuel pump; check for leaks at fill
cap, fuel lines/rail, and fuel pump; replace lines every two
years.
▶
Engine Mounts
100 12 M
1000
(1600)
Inspect
106
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOURS CALENDAR
MILES
(KM)
Exhaust muffler/
pipe
100 12 M
1000
(1600)
Inspect
D
Ignition Timing
100 12 M
1000
(1600)
Inspect
▶
Wiring
100 12 M
1000
(1600)
Inspect for wear, routing, security; apply dielectric grease
to connectors subjected to water, mud, etc.
D
Clutches (Drive/
Driven)
100 12 M
1000
(1600)
Inspect; clean; replace worn parts
D
Front Wheel
Bearings
100 12 M
1000
(1600)
Inpsect; replace as needed
Spark Arrester
300 36 M
3000
(4800)
Clean out
D
Toe Adjustment
-
Inspect periodically; adjust as needed
▶ Perform these procedures more often for vehicles subjected to severe use.
107
MAINTENANCE
ITEM LUBE METHOD
Drive Chain POLARIS Chain Lube or SAE 80/90 See page 135
Front Suspension (A-Arm Pivots) POLARIS All Season Grease or grease
conforming to NLGI No. 2
Inspect; tighten fasteners; grease (also
after washing ATV or driving in water).
▶ Perform these procedures more often for vehicles subjected to severe use.
110
MAINTENANCE
ENGINE OIL
OIL RECOMMENDATIONS
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart
section. POLARIS recommends the use of POLARIS PS-4 Extreme Duty 10W-50 4-Cycle Oil for this
vehicle. Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive
oil. See page 167 for the part numbers of POLARIS products.
NOTICE
Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the
recommended oil. Never substitute or mix oil brands.
112
MAINTENANCE
OIL CHECK
Maintain the oil level within the safe range on the dipstick. Do not overfill.
1. Position the vehicle on a level surface.
2. Remove the dipstick
q
. Wipe it dry with a clean cloth.
3. Reinstall the dipstick completely.
4. Remove the dipstick and check the oil level.
TIP
A rising oil level between checks in cool weather driving can indicate
contaminants such as gas or moisture collecting in the crankcase. If the
oil level is over the full/safe mark, change the oil immediately.
5. Add the recommended oil as needed.
6. Reinstall the dipstick.
w
Safe Range
e
Add Oil
r
Full
113
MAINTENANCE
OIL CHANGE
1. Position the vehicle on a level surface. Set the parking brake.
2. Clean the area around the pre-filter plug.
3. Start the engine. Allow it to idle for two to three minutes.
4. Stop the engine.
WARNING
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
5. Place a drain pan under the engine crankcase.
6. Remove the pre-filter plug. Allow the oil to drain completely.
7. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry.
8. Clean the pre-filter plug. Install a new sealing washer on the plug. The sealing surfaces on the plug
and crankcase should be clean and free of burrs, nicks or scratches.
114
MAINTENANCE
9. Reassemble the pre-filter screen and spring to the pre-filter plug.
10.Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm).
11. Remove the dipstick. Add 29 oz. (850 ml) of the recommended oil. Do not overfill. See the
Specifications chapter for capacities.
12.Reinstall the dipstick.
13.Start the engine. Allow it to idle for one to two minutes.
14.Stop the engine and inspect for leaks.
15.Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.
16.Dispose of used oil properly.
115
MAINTENANCE
TRANSMISSION (MAIN GEARCASE)
Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart
beginning on page 101. POLARIS recommends the use of AGL Gearcase Lubricant & Transmission
Fluid for this vehicle.
FLUID CHECK
The fill plug
q
is located on the rear of the gearcase. The drain
plug
w
is located on the bottom of the gearcase. Access the fill
plug through the left rear wheel well. Maintain the fluid level at
the bottom of the fill plug hole threads.
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. View the oil level through the fill hole.
4. Add the recommended fluid as needed.
5. Reinstall the fill plug.
116
MAINTENANCE
FLUID CHANGE
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Place a drain pan under the drain plug.
4. Remove the drain plug. Allow the fluid to drain completely.
5. Clean the drain plug.
6. Reinstall the drain plug with a new o-ring. Torque to 14 ft. lbs. (19 Nm).
7. Add the recommended oil. Maintain the oil level at the bottom of the fill plug hole threads.
8. Reinstall the fill plug.
9. Check for leaks.
10.Discard used fluid properly.
117
MAINTENANCE
Gearcase Capacity
Outlaw 110
11.8 oz. (350 ml)
Sportsman 110 11.8 oz. (350 ml)
CYLINDER HEAD TORQUE
Have your dealer or other qualified person check the ATV cylinder head for proper torque at first service
— or after 25 hours.
VEHICLE IMMERSION
NOTICE
If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly
inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can
provide this service.
If it’s impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. This
procedure will allow for short-term operation only to drive the ATV to a trailer or towing vehicle.
118
MAINTENANCE
1. Move the vehicle to dry land or, at minimum, to water below the footrests.
2. Check the air box for any water and dry if water is present.
3. Remove the spark plug.
4. Turn the engine over several times using the electric start.
5. Dry the spark plug and reinstall it, or install a new plug.
6. Attempt to start the engine. If necessary, repeat the drying procedure.
7. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your
POLARIS dealer can provide the required service.
8. If water has been ingested into the transmission follow the procedure on page 122 for drying the
CVT.
SPARK PLUGS
SPARK PLUG GAP/TORQUE
Refer to the specifications section beginning on page 159 for spark plug and gap specifications.
119
MAINTENANCE
NOTICE
Spark plug condition is indicative of engine operation. The spark plug firing end condition should be
read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the
spark plug for correct color. Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs or their equivalent.
WARNING
A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark
plug for inspection.
SPARK PLUG CONDITION
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The
electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and
the service.
120
MAINTENANCE
TIP
The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper
spark plug or incorrect throttle body adjustments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer
over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive
oil, use of non-recommended injection oil or incorrect throttle body adjustments.
SPARK PLUG REMOVAL AND REPLACEMENT
1. Remove the spark plug cap.
2. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-
clockwise.
3. Reverse the procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).
121
MAINTENANCE
CONSTANT VARIABLE TRANSMISSION (CVT) SYSTEM
WARNING
Failure to comply with the instructions in this warning can result in severe injury or death.
Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure
may occur at a high speed. The CVT system has been precision balanced. Any modification will cause
the system to be out of balance, creating vibration and additional loads on components.
• Always follow all recommended maintenance procedures. See your POLARIS dealer, or other
qualified person, for service and repair assistance.
• This CVT system is intended for use on POLARIS products only. Do not install it in any other
product.
• Always make sure the CVT housing is securely in place during operation.
CVT DRYING
There may be some instances when water is accidently ingested into the CVT system. Use the
following instructions to dry it out before operating. The drain plug is located on the bottom of the CVT
cover.
122
MAINTENANCE
1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug.
2. Shift the transmission to neutral. Set the parking brake.
3. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt
and clutches. Do not hold the throttle wide open for more than 10 seconds.
4. Allow the engine RPM to settle to idle speed.
5. Test for belt slippage. If the belt slips, repeat the process.
6. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist.
NOTICE
Exposure to salt water will cause corrosion to metal components. If your vehicle is operated in salt
water areas, rinse it off frequently with fresh water.
123
MAINTENANCE
SPARK ARRESTER
WARNING
Failure to heed the following warnings while servicing the spark arrester could result in serious injury
or death.
• Do not perform service on the spark arrester while the system is hot. Allow components to cool
sufficiently before proceeding.
• Wear eye protection and gloves.
• Never operate without the spark arrestor.
• Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.
To remove accumulated carbon, clean the spark arrester at the intervals recommended in the Periodic
Maintenance Chart section.
1. Remove the six bolts and remove the arrester from the end of the muffler.
2. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components
are warm. If necessary, blow debris from the screen with compressed air.
124
MAINTENANCE
SPEED CONTROL AND THROTTLE SYSTEM
NOTICE
Per ANSI / SVIA-1-2010 (sec. 6.2) AS DELIVERED TO THE CONSUMER, the speed of youth models
is restricted to 10 MPH or less for the Y-6+ models and 15 MPH or less for the Y-10+ models.
The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the
consumer’s request, remove or adjust any speed limiting devices.
This vehicle has an adjustable speed control system that controls engine RPM and speed of the
vehicle. The speed limiting device may be adjusted by supervising adults when they determine that
their child is capable of safely handling additional speed.
Per ANSI / SVIA-1-2010 (sec. 6.1) the unrestricted top speed is 15 MPH or less for the Y-6+ models
and 30 MPH or less for the Y-10+ models.
126
MAINTENANCE
THROTTLE STOP / SPEED CONTROL SYSTEM
Use the following procedure to control how far the
throttle opens.
1. Loosen the jam nut
w
.
2. Turn the screw
q
inward to reduce speed or outward
to increase speed.
3. Tighten the jam nut after adjusting.
THROTTLE CABLE ADJUSTMENT
Always check the throttle for smooth operation before
riding. Periodically check the throttle freeplay. It should be
kept between 1/16" and 1/8" (1.5 - 3.2 mm). If adjustment is
required, turn the adjustment nut
q
until the freeplay falls in
to the acceptable limit.
127
MAINTENANCE
BRAKE FREEPLAY
Check (measure) the freeplay of the front and rear brakes at the intervals recommended in the Periodic
Maintenance Chart beginning on page 101. If the freeplay isn’t at specification, adjust the freeplay as
outlined on the following pages.
Brake Freeplay Specifications
Front Brake Rear Brake
.08"-.12" (2-3 mm) .08"-.12" (2-3 mm)
FRONT BRAKE ADJUSTMENT
1. Position the vehicle on a level surface.
2. Shift the transmission to neutral.
3. Elevate the front of the vehicle by placing a suitable stand under the frame. The front tires should be
slightly off the ground.
4. While rotating the left front wheel, tighten the upper front brake adjuster nut
q
on the right-hand
control.
128
MAINTENANCE
5. When you begin to feel a slight drag in wheel rotation, loosen the adjuster nut one full turn.
6. While rotating the right front wheel, tighten the lower front brake adjuster nut
q
on the right-hand
control.
7. When you begin to feel a slight drag in wheel rotation, loosen the adjuster nut one full turn.
8. Verify that the right-hand brake functions correctly.
9. Verify that brake lever freeplay is at specification.
10.Carefully lower the vehicle to the ground.
129
MAINTENANCE
REAR BRAKE ADJUSTMENT
1. Position the vehicle on a level surface.
2. Shift the transmission to neutral.
3. Elevate the rear of the vehicle by placing a suitable stand under the frame. The rear tires should be
slightly off the ground.
4. While rotating the rear wheels, tighten the rear brake wing nut
q
at the rear brake drum.
5. When you begin to feel a slight drag in wheel rotation, loosen the wing nut one full turn.
6. Verify that the left hand brake functions correctly.
7. Verify that brake lever freeplay is at specification.
8. Carefully lower the vehicle to the ground.
130
MAINTENANCE
BRAKE LEVER TRAVEL
Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart beginning on
page 101. When freeplay specifications can no longer be obtained through adjustment as outlined on
the preceding pages, use the following information to determine when to service the brakes.
131
MAINTENANCE
Service the brakes when brake lever travel reaches the total lever
travel measurement listed in the table below. Always service the
brakes when there is no longer sufficient stopping ability at the
specified lever travel setting.
Component
Total Lever Travel
Front Brake Lever
1 3/4" (45 mm)
Rear Brake Lever
2 1/2" (65 mm)
132
MAINTENANCE
TOE ALIGNMENT
Recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. Check using the procedure below.
WARNING
Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to
adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS
dealer or other qualified service facility.
1. Position the vehicle on a level surface.
2. Place the handlebars in a straight-ahead position.
3. Tie a length of string between two stands. Position the stands so that the string is flush with the side
of the rear tire. If available, you may use a long straightedge instead of string.
4. Measure the distance from the string to the rim at the front (1) and rear (2) of the front rim. The rear
measurement should be 1/16"-1/8" (2-3 mm) more than the front measurement on each side of the
vehicle to obtain the recommended 1/8" to 1/4" (3-6 mm) toe out alignment.
5. Repeat the measurement procedure on the other side of the vehicle.
133
MAINTENANCE
6. If you discover improper alignment, see your POLARIS dealer for service.
STEERING INSPECTION
Check the steering assembly periodically for loose nuts and bolts. If loose nuts and bolts are found, see
your POLARIS dealer or other qualified service facility before operating the vehicle.
CAMBER AND CASTER
The camber and caster are non-adjustable.
SHOCK SPRING ADJUSTMENT
WARNING
Uneven adjustment may cause poor handling of the vehicle, which could
result in an accident. Always adjust both the left and right spring preloads
equally or have your POLARIS dealer perform the adjustments.
The front and rear shock absorber springs are adjustable to increase or
decrease spring tension. Rotate the adjuster
q
either clockwise or counter-
clockwise to make adjustments.
134
MAINTENANCE
DRIVE CHAIN
DRIVE CHAIN LUBRICATION
Lubricate the drive chain with POLARIS chain spray lube or an approved chain lube at the general
lubrication interval specified in the Periodic Maintenance Chart section. Lubricate more often under
severe use, such as in dirty or wet conditions. See page 167 for the part numbers of POLARIS
products.
NOTICE
Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive
chain failure. Don't use a high pressure washer or gasoline to clean the drive chain.
Adjusting or operating the vehicle with improper rear drive chain slack can result in severe damage to
the transmission and drive components. Always make sure the slack is within the stated
specifications.
135
MAINTENANCE
DRIVE CHAIN SLACK
1. Check the amount of chain slack by moving the vehicle
slightly forward to gain slack at the top side of the chain.
2. Collapse the suspension with an adjustable (buckle type)
trailer tiedown strap. Fasten the strap around the axle and
rear bumper tube.
3. Tighten the strap until a straight line can be drawn from the
rear axle to the gearcase output shaft intersecting the swing
arm pivot. This establishes the tightest chain position.
4. Pull down on the chain tensioner
q
to move it out of the way,
then measure chain slack. It should have 1/4"-1/2" (6-12 mm)
deflection.
5. If the chain needs adjustment, use the procedure cited below.
136
MAINTENANCE
DRIVE CHAIN SLACK ADJUSTMENT
1. Loosen the four rear housing mount bolts
q
.
2. Loosen the chain adjuster lock nut.
3. Turn the chain adjuster
w
clockwise to 1/4"-1/2" (6-12 mm)
deflection.
4. Tighten the chain adjuster lock nuts to 18 ft. lbs. (25 Nm). Hold
the adjuster stud securely while tightening the nut to avoid
breaking the stud.
5. Tighten the four rear housing mount bolts to 43 ft. lbs. (60 Nm).
137
MAINTENANCE
AIR FILTER
Always change the air filter at the intervals outlined in the Periodic Maintenance Chart section.
1. Remove the seat. See page 49.
2. Release the air box cover spring clips and remove the cover.
3. Remove the foam air filter. Wash the foam filter in warm soapy water, then rinse and let dry. If the
filter is damaged, install a new foam filter.
4. Apply a commercially available foam filter lubricant to the foam filter.
5. Clean away any oil or sediments in the air box.
6. Reinstall the filter and air box cover. Secure the clips.
7. Reinstall the seat.
NOTICE
Never operate the vehicle with the filter element removed. Dirt will enter the engine, causing rapid
wear and severe damage to the engine.
138
MAINTENANCE
HANDLEBAR ADJUSTMENT
WARNING
Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can
cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious
personal injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer or
other qualified service person for service.
140
MAINTENANCE
The handlebars can be adjusted for rider preference.
1. Remove the pod to access the handlebar bolts
q
.
Loosen the four bolts.
2. Adjust the handlebar to the desired height. Be sure the
handlebars do not hit the gas tank or any other part of
the vehicle when turned fully to the left or right.
3. Lightly tighten each bolt equally to prevent uneven gaps
in the block. Torque the bolts to 7.3 ft. lbs. (10 Nm).
141
MAINTENANCE
TIRES
WARNING
Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed
tires will affect vehicle handling and could cause an accident resulting in serious injury or death.
Always follow all tire maintenance procedures as outlined in this manual and on the labels on the
vehicle. Always use original equipment size and type when replacing tires.
TIRE TREAD DEPTH
Always replace tires when tread depth is worn to 1/8" (3 mm)
q
or less.
142
MAINTENANCE
WHEEL REMOVAL
1. Stop the engine and lock the parking brake.
2. Loosen the wheel bolts slightly.
3. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
4. Remove the wheel bolts and remove the wheel.
WHEEL INSTALLATION
1. Lock the parking brake.
2. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the
outside and rotation arrows on the tire point toward forward rotation.
3. Install the wheel bolts and finger tighten them.
4. Lower the vehicle to the ground.
143
MAINTENANCE
5. Securely tighten the bolts to 22 ft. lbs. (30 Nm).
WHEEL HUB TIGHTENING
Front wheel bearing tightness and spindle nut retention are critical component operations. All service
must be performed by your authorized POLARIS dealer or other qualified service facility.
AXLE AND WHEEL NUTS
Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer can assist.
LIGHTS
DAYTIME RUNNING LIGHTS LAMP REPLACEMENT (IF EQUIPPED)
If the daytime running lights do not operate, replace the lamps. POLARIS recommends that you install
replacement lamps obtained from your authorized POLARIS dealer.
1. Remove the front cover (OUTLAW only).
2. Disconnect the lights from the harness.
3. Remove the rubber cover from the back of the light assembly.
144
MAINTENANCE
4. Press the lamp retainer inward and turn it counter-clockwise to remove it. Note position of the lamp
positioning tab, then carefully pull the lamp out.
5. Install the new lamp. Make sure the filament is horizontal.
6. Reinstall the lamp retainer. Press the retainer inward and turn it clockwise about 1/4 turn.
7. Start the engine to make sure the lights come on. If the lights do not operate, see your POLARIS
dealer for service.
8. Reinstall the rubber cover, and reconnect the lights to the harness.
9. Reinstall the front cover (OUTLAW only).
INDICATOR LIGHT LAMP REPLACEMENT
1. Remove the handlebar cover or pod to access the lamps.
2. Remove the indicator wire connections from the harness.
3. Remove the nut from the back side of the indicator lamp.
4. Remove the lamp.
145
MAINTENANCE
5. Apply dielectric grease to the socket and install the new lamp.
6. Reverse the steps to reinstall all components.
TAIL LIGHT LAMP REPLACEMENT
If the brake light doesn't work, the lamp
q
may need to be replaced.
1. Remove the two screws
e
securing the lens cover. Remove the
lens cover
w
.
2. Remove the lamp and replace it with a new recommended lamp.
3. Test the light for proper operation.
4. Reinstall the lens cover.
146
MAINTENANCE
BATTERY
WARNING
Improperly connecting or disconnecting battery cables can result in an explosion and cause serious
injury or death. When removing the battery, always disconnect the negative (black) cable first. When
reinstalling the battery, always connect the negative (black) cable last.
The battery in your POLARIS ATV is a sealed battery. The sealing strip cannot be removed. Never add
water to this type of battery.
Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the
corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup
water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric
grease or petroleum jelly to reduce oxidation and excessive power consumption.
BATTERY REMOVAL
1. Remove the battery hold-down strap.
2. Disconnect the black (negative) battery cable first.
147
MAINTENANCE
3. Disconnect the red (positive) battery cable next.
4. Lift the battery out of the ATV.
BATTERY INSTALLATION AND CONNECTIONS
Always install a fully charged battery. Using a new battery that has not been fully charged can damage
the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary,
use a .5 amp battery charger
1. Set the battery in its holder.
2. Coat the terminals with dielectric grease or petroleum jelly.
3. Connect and tighten the red (positive) cable first.
4. Connect and tighten the black (negative) cable last.
5. Attach the hold-down strap.
6. Verify that cables are properly routed.
148
MAINTENANCE
BATTERY STORAGE
Whenever the vehicle is not used for a period of three months or more, remove the battery from the
vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery
voltage each month during storage and recharge as needed to maintain a full charge.
BATTERY CLEANING
Keeping your ATV clean will not only improve its appearance but it can also extend the life of various
components.
NOTICE
High water pressure may damage components. POLARIS recommends washing the vehicle by hand
or with a garden hose, using mild soap.
Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not
allow these types of products to contact the vehicle.
149
MAINTENANCE
CLEANING
WASHING THE VEHICLE
The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap
and water.
1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The
water may damage components and could remove paint and decals. Avoid directing the water stream
at the following items:
• Wheel bearings
• Radiator
• Transmission seals
• Brakes
• Cab and body panels
150
MAINTENANCE
• Labels and decals
If warning and safety labels are damaged, contact your POLARIS dealer for free replacement.
Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any
water that may have entered the engine or exhaust system.
WASHING TIPS
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may
contain dirt particles that will scratch the finish.
POLISHING
POLARIS recommends the use of common household aerosol furniture polish for polishing the finish
on your POLARIS vehicle. Follow the instructions on the container.
• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
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MAINTENANCE
• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may
contain dirt particles that will scratch the finish.
STORAGE
EXTERIOR
Make necessary repairs and clean the vehicle as recommended. See page 147.
BATTERY STORAGE
Remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool,
dry place. Check battery voltage each month during storage and recharge as needed to maintain a full
charge.
STABILIZE THE FUEL
1. Fill the fuel tank with the recommended fuel.
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MAINTENANCE
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel
treatments or stabilizers. Follow the instructions on the container for the recommended amount.
Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from
pistons, rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel
delivery system.
FOG THE ENGINE
1. Treat the fuel system with POLARIS Carbon Clean. Follow the instructions on the container. Start
the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the
engine.
2. Remove the spark plug and add 2-3 tablespoons of engine oil. To access the plug hole, use a
section of clear 1/4” hose and a small plastic squeeze bottle filled with the premeasured amount of
oil.
3. Reinstall the spark plug. Torque to specification. See page 119.
4. Apply dielectric grease to the inside of the spark plug cap. Do not reinstall the cap onto the plug at
this step.
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MAINTENANCE
5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands,
coating the cylinder with a protective film of fresh oil.
6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely
drained of gasoline.
7. Reinstall the spark plug cap to the spark plug.
ENGINE OIL
Change the oil. See page 114.
AIR FILTER / AIR BOX
Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air box. Drain the sediment tube.
FLUID LEVELS
Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on
page 101.
• Transmission Oil
• Engine Oil
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MAINTENANCE
LUBRICATE
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance
Chart beginning on page 101.
STORAGE AREA / COVERS
1. Make sure tire pressure is at specification.
2. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not touching
the ground.
3. Be sure the storage area is well ventilated.
4. Cover the vehicle with an appropriate cover. Do not use plastic or coated materials. They do not
allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
TRANSPORTING THE ATV
1. Stop the engine. Place the transmission in gear. Lock the parking brake.
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MAINTENANCE
2. Secure the fuel cap, oil cap and seat.
NOTICE
Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. The rack,
bumper or handlebars do not offer enough support for tie-down while transporting. For high-speed
trailering, it is recommended to remove the safety flag.
156
MAINTENANCE
SPECIFICATIONS
OUTLAW 110
POLARIS OUTLAW 110
Rider Capacity/Maximum Weight 1 Rider/180 lbs. (81.7 kg)
Dry Weight 278 lbs. (126 kg)
Length/Width/Height 61.75" (157 cm) / 36.75" (93 cm) / 38.5" (98 cm)
Wheel Base 41.5" (105 cm)
Ground Clearance 4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame
Engine type 4-Stroke
Displacement 112cc
Cooling Air Cooled
Bore x Stroke 61 mm x 57.8 mm
159
SPECIFICATIONS
POLARIS OUTLAW 110
Alternator Output 80 watts
Compression Ratio 9.5:1
Lubrication Wet Sump
Oil Capacity 30 oz. (900 ml)
Fuel Capacity 1.7 gallons (6.4 liters)
Fuel Reserve Capacity .23 gallons (.86 liters)
Starting System Electric
Fuel System Electronic fuel injection
Throttle Body Size 22 mm
Ignition System CDI
Ignition Timing 32° +/- 2° @ 5000 RPM
160
SPECIFICATIONS
POLARIS OUTLAW 110
Spark Plug / Gap NGK CR6HSA / 0.6-0.7 mm
Drive System Automatic Automatic CVT
Final Drive Chain
Front Suspension Single A-arm with 5" (12.7 cm) of travel
Rear Suspension Swing arm with 6" (15.2 cm) of travel
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front Tires 19 x 7 - 8 (3 psi/20.7 kPa)
Rear Tires 18 x 9.5 - 8 (3 psi/20.7 kPa)
Brake Light Standard
Daytime Running Lights Standard
161
SPECIFICATIONS
SPORTSMAN 110
POLARIS SPORTSMAN 110
Rider Capacity/Maximum Weight 1 Rider/180 lbs. (81.7 kg)
Dry Weight 289 lbs. (131 kg)
Length/Width/Height 61.75" (157 cm) / 36.75" (93 cm) / 38.5" (98 cm)
Wheel Base 41.5" (105 cm)
Ground Clearance 4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame
Engine type 4-Stroke
Displacement 112cc
Cooling Air Cooled
Bore x Stroke 61 mm x 57.8 mm
Alternator Output 80 watts
162
SPECIFICATIONS
POLARIS SPORTSMAN 110
Compression Ratio 9.5:1
Lubrication Wet Sump
Oil Capacity 30 oz. (900 ml)
Fuel Capacity 2 gallons (7.7 liters)
Fuel Reserve Capacity .22 gallons (.85 liters)
Starting System Electric
Fuel System Electronic fuel injection
Throttle Body Size 22 mm
Ignition System CDI
Ignition Timing 32° +/- 2° @ 5000 RPM
Spark Plug / Gap NGK CR6HSA / 0.6-0.7 mm
163
SPECIFICATIONS
POLARIS SPORTSMAN 110
Drive System Automatic CVT
Final Drive Chain
Front Suspension Single A-arm with 5" (12.7 cm) of travel
Rear Suspension Swing arm with 6" (15.2 cm) of travel
Front Rack Capacity 15 lbs. (7 kg)
Rear Rack Capacity 30 lbs. (14 kg)
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front Tires 19 x 7 - 8 (3 psi/20.7 kPa)
Rear Tires 18 x 9.5 - 8 (3 psi/20.7 kPa)
164
SPECIFICATIONS
166
GEARCASE / TRANSMISSION LUBRICANTS
PART NUMBER DESCRIPTION
2878068 AGL Full Synthetic Gearcase Lubricant & Transmission
Fluid (qt./.95 l)
2878069 AGL Full Synthetic Gearcase Lubricant & Transmission
Fluid (gal./3.8 l)
2872348 Chain Lube, Aerosol
GREASE
PART NUMBER DESCRIPTION
2871322 All Season Grease (3 oz./89 ml cartridge)
2871423 All Season Grease (14 oz./414 ml cartridge)
168
POLARIS PRODUCTS
170
TROUBLESHOOTING
ENGINE DOESN’T TURN OVER
POSSIBLE CAUSE SOLUTION
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
ENGINE TURNS OVER, FAILS TO START
POSSIBLE CAUSE SOLUTION
Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
171
TROUBLESHOOTING
POSSIBLE CAUSE SOLUTION
Fouled or defective spark plug Inspect plug and replace if necessary
No spark to spark plug Inspect plug and replace if necessary
Water or fuel in crankcase Your POLARIS dealer can assist
Clogged Fuel Filter Your POLARIS dealer can assist
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure Your POLARIS dealer can assist
172
TROUBLESHOOTING
ENGINE PINGS OR KNOCKS
POSSIBLE CAUSE SOLUTION
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing Your authorized dealer can assist
Incorrect spark plug gap or heat
range
Set gap to specs or replace plugs
ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES
POSSIBLE CAUSE SOLUTION
Fouled or defective spark plug(s) Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires Your POLARIS dealer can assist
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
173
TROUBLESHOOTING
POSSIBLE CAUSE SOLUTION
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Throttle release switch malfunction Your POLARIS dealer can assist
Other mechanical failure Your POLARIS dealer can assist
POSSIBLE LEAN FUEL
CAUSE
SOLUTION
Low or contaminated fuel Add or change fuel, clean the fuel system
Kinked or plugged fuel tank
vent line
Inspect and replace
174
TROUBLESHOOTING
POSSIBLE LEAN FUEL
CAUSE
SOLUTION
Low octane fuel Replace with recommended fuel
Clogged air filter Your POLARIS dealer can assist
Incorrect fuel Replace with recommended fuel
ENGINE STOPS OR LOSES POWER
POSSIBLE CAUSE SOLUTION
Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect, clean and/or replace spark plugs
175
TROUBLESHOOTING
POSSIBLE CAUSE SOLUTION
Worn or defective spark plug wires Your POLARIS dealer can assist
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Throttle release switch malfunction Your POLARIS dealer can assist
Overheated engine Clean engine exterior. Your POLARIS dealer can assist.
Other mechanical failure Your POLARIS dealer can assist
176
TROUBLESHOOTING
WARRANTY
LIMITED WARRANTY
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH
LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or
workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency
requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and
when maintenance and installation are in accordance with POLARIS recommendations.
This warranty covers parts and labor charges for repair or replacement of defective parts and begins on
the date of purchase by the original retail purchaser. This warranty is transferable to another owner
during the warranty period through a POLARIS dealer, or other qualified person, but any such transfer
will not extend the original term of the warranty. The duration of this warranty may vary by international
region based upon local laws and regulations.
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WARRANTY
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to
POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the
registration for warranty. No verification of registration will be sent to the purchaser as the copy of the
Warranty Registration Form will be your proof of warranty coverage. If you have not signed the original
registration and received the customer copy, please contact your dealer immediately. NO WARRANTY
COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial
dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation.
Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.
WARRANTY COVERAGE AND EXCLUSIONS
LIMITATIONS OF WARRANTIES AND REMEDIES
This POLARIS limited warranty excludes any failures that are not caused by a defect in material or
workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This
warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper
handling. This warranty also does not cover any vehicle, component, or part that has been altered
structurally, modified, neglected, improperly maintained or used for racing, competition or purposes
other than for which it was designed.
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WARRANTY
This warranty excludes damages or failures resulting from improper lubrication; improper engine timing;
improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator
error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow,
water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified
components; use of aftermarket or unapproved components, accessories, or attachments; use of
unapproved software or calibration; unauthorized repairs; or repairs made after the warranty period
expires or by an unauthorized repair center.
This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other
than a defect in materials or workmanship and provides no coverage for consumable components,
general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/
or contamination for which they were not designed or not intended, including but not limited to the
following items:
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WARRANTY
• Wheels and tires
• Suspension components
• Brake components
• Seat components
• Clutches and components
• Steering components
• Batteries
• Light bulbs/Sealed beam lamps
• Filters
• Lubricants
• Bushings
• Finished and unfinished surfaces
• Carburetor/Throttle body components
• Engine components
• Drive belts
• Hydraulic components and fluids
• Circuit breakers/Fuses
• Electronic components
• Spark plugs
• Sealants
• Coolants
• Bearings
LUBRICANTS AND FLUIDS
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the
use of POLARIS engine oil.
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WARRANTY
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by
this warranty.
This warranty provides no coverage for personal loss or expense, including mileage, transportation
costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of
product use, loss of profits, or loss of vacation or personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION,
REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS.
THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY
PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY
PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,
WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,
NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM
THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED
TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE
ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES
NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR
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WARRANTY
LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE
DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU
IF INCONSISTENT WITH CONTROLLING STATE LAW.
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When
requesting warranty service you must present your copy of the Warranty Registration Form to the
dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR
RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may
use any POLARIS Servicing Dealer to perform warranty service.
In the Country where your product was purchased:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or
are traveling within the country where your product was purchased, Warranty and Service Bulletin
repairs may be requested from any authorized POLARIS dealer that sells the same line as your
product.
Outside the Country where your product was purchased:
If you are traveling temporarily outside the country where your product was purchased, you should take
your product to an authorized POLARIS dealer. You must show the dealer photo identification from the
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WARRANTY
country of the selling dealer's authorized location as proof of residence. Upon residence verification,
the servicing dealer will be authorized to perform the warranty repair.
If you move:
If you move to another country, be sure to contact POLARIS Customer Assistance and the customs
department of the destination country before you move. Product importation rules vary considerably
from country to country. You may be required to present documentation of your move to POLARIS in
order to continue your warranty coverage. You may also be required to obtain documentation from
POLARIS in order to register your product in your new country. You should warranty register your
product at a local POLARIS dealer in your new country immediately after you move to continue your
warranty coverage and to ensure that you receive information and notices regarding your vehicle.
If you purchase from a private party:
If you purchase a POLARIS product from a private party, to be kept and used outside of the country in
which the product was originally purchased, all warranty coverage will be denied. You must
nonetheless register your product under your name and address with a local POLARIS dealer in your
country to ensure that you receive safety information and notices regarding your product.
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WARRANTY
EXPORTED PRODUCTS
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE
BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE
SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have
received authorization for export from POLARIS. Dealers may not give authorization for export. You
should consult an authorized dealer to determine this product's warranty or service coverage if you
have any questions. This policy does not apply to products registered to government officials or military
personnel on assignment outside the country of the selling dealer's authorized location. This policy
does not apply to Safety Bulletins.
NOTICE
If your product is registered outside of the country where it was purchased and you have not followed
the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage
of any kind, other than safety bulletins. Products registered to government officials or military personnel
on assignment outside of the country where the product was purchased will continue to be covered by
the Limited Warranty.
Please work with your dealer to resolve any warranty issues. Should your dealer require any additional
assistance, they will contact the appropriate person at POLARIS.
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WARRANTY
This warranty gives you specific legal rights, and you may also have other rights which vary from state
to state or in different countries. If any of the above terms are void because of federal, state, local law,
all other warranty terms will remain in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
U.S.A. EPA EMISSIONS LIMITED WARRANTY
This emissions limited warranty is in addition to the POLARIS standard limited warranty for your
vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified
vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection
Agency emission regulations. POLARIS warrants that the vehicle is free from defects in materials and
workmanship that would cause it to fail to meet these regulations.
The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the
date of purchase by original retail purchaser and continues for a period of 500 hours of engine
operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of
purchase, whichever comes first. The warranty period for ATVs less than 100cc emissions-certified
vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250
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WARRANTY
hours of engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from
the date of purchase, whichever comes first. This EPA emissions warranty period is extended for at
least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA
emissions warranty period does not further extend if you purchase additional warranty coverage in the
form of a service contract or other paid warranty extension, but emission-related parts may be covered
subject to the terms of any such paid service contract or paid warranty extension.
This emissions limited warranty covers components whose failure increases the vehicle's regulated
emissions, and it covers components of systems whose only purpose is to control emissions. Repairing
or replacing other components not covered by this warranty is the responsibility of the vehicle owner.
This emissions limited warranty does not cover components whose failure does not increase the
vehicle's regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to the following
systems:
• Air-induction system
• Fuel system
• Ignition system
• Exhaust gas recirculation systems
The following parts are also considered emission-related components for exhaust emissions:
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WARRANTY
The following parts are considered emission-related components for evaporative emissions:
• Fuel Tank
• Fuel Cap
• Fuel Line
• Fuel Line Fittings
• Clamps*
• Pressure Relief Valves*
• Control Valves*
• Control Solenoids*
• Electronic Controls*
• Vacuum Control Diaphragms*
• Control Cables*
• Control Linkages*
• Purge Valves
• Vapor Hoses
• Liquid/Vapor Separator
• Carbon Canister
• Canister Mounting Brackets
• Carburetor Purge Port Connector
*As related to the evaporative emission control system.
Emission-related components also include any other part whose only purpose is to reduce emissions or
whose failure will increase emissions without significantly degrading engine/equipment performance.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS,
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WARRANTY
repair or replacement of any defective materials, components or products. THE REMEDIES SET
FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON
FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,
NEGLIGENCE OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION
TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long
an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling
state law.
This limited warranty excludes failures not caused by a defect in material or workmanship. This limited
warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use.
This limited warranty also does not cover any engine that has been structurally altered, or when the
vehicle has been used in racing competition. This limited warranty also does not cover physical
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WARRANTY
damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of
POLARIS.
Owners are responsible for performing the scheduled maintenance identified in the owner's manual.
POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's
improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission control devices or
systems on your vehicle. An authorized POLARIS dealer, or other qualified person, can perform any
service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts, however
equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part
supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission
controls. Tampering with emission controls is prohibited by federal law.
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WARRANTY
CALIFORNIA RESIDENTS
Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions. Only the 50-state
models are certified for sale in California. The 50-state models available for sale in California are
identified by the letter “B” in the ninth position of the model number (e.g., R16RTE87B). The POLARIS
50-state models are designed and built with features such as a reduced cargo box capacity. Any
modifications to these features may be a violation of the applicable California regulations and may void
this limited emissions warranty offered by the manufacturer.
If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS
Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
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WARRANTY
192
196
A
Additives /
Miscellaneous............... 169
Age Restrictions ............... 18
Air Filter ........................ 138
B
Battery.......................... 147
Boots ............................. 38
Brake Freeplay............... 128
Brakes............................ 70
C
Camber and Caster ......... 134
Carrying a Passenger ........ 21
Cleaning ....................... 150
Clothing .......................... 38
Constant Variable
Transmission (CVT)
System........................ 122
Crankcase Emission
Control System ............. 100
Crossing Hillsides ............. 26
Cylinder Head Torque .......118
D
Descending Hills
Improperly ..................... 24
Drive Chain ................... 135
Driving Downhill................ 90
Driving in Reverse............. 87
Driving on a Sidehill
(Sidehilling) .................... 89
Driving on Slippery
Surfaces........................ 93
Driving Over Obstacles ...... 94
Driving Procedure ............. 86
Driving Through Water ....... 95
Driving Uphill ................... 88
E
Electromagnetic
Interference.................. 100
Emissions Limited
Warranty ..................... 185
Engine Doesn’t Turn
Over ........................... 171
Engine Lubricant............. 167
Engine Runs Irregularly,
Stalls or Misfires............ 173
Engine Start Button ........... 66
197
Engine Stop Switch ........... 65
Engine Stops or Loses
Power ......................... 175
Engine Turns Over, Fails
to Start ........................ 171
Equipment Modifications .. 34–
35
Exhaust Emission
Control System ............. 100
Exported Products .......... 184
Exposure to Exhaust.......... 19
Eye Protection.................. 37
F
Failure to Inspect Before
Operating ...................... 20
Fuel System .................... 75
G
Gearcase / Transmission
Lubricants.................... 168
Gloves............................ 38
Grease ......................... 168
H
Handlebar Adjustment ..... 140
Handling Gasoline............. 19
Hauling Cargo .................. 96
Helmet............................ 37
Horn Button ..................... 66
Hot Exhaust Systems......... 32
How To Obtain Warranty
Service........................ 182
I
Improper Cargo Loading..... 31
Improper Hill Climbing........ 25
Improper Tires and
Maintenance .................. 30
Improper Vehicle
Modifications .................. 29
Indicator Lights................. 73
J
Jumps and Stunts ............. 24
K
Know Your ATV ................ 49
198
L
Lights ........................... 144
Limited Warranty............. 177
M
Main Key Switch ............... 65
Maintenance Chart Key .... 102
Maintenance Log ............ 193
Making Turns ................... 87
Messages to Parents
and Young Operators .........7
N
Noise Emission Control
System.......................... 99
O
Oil Change .....................114
Oil Check .......................113
Operating at Excessive
Speeds ......................... 22
Operating Improperly in
Reverse ........................ 28
Operating in Unfamiliar
Terrain .......................... 27
Operating on Frozen
Bodies of Water .............. 30
Operating on Pavement..... 21,
23
Operating on Public
Roads ........................... 22
Operating on Slippery
Terrain .......................... 28
Operating on Steep Hills..... 25
Operating Over Obstacles... 29
Operating Without
Instruction...................... 18
Operation on Public
Lands in the U.S.A. .......... 99
Outlaw 110
Specifications ............... 159
P
Parking on a Hill or Incline... 92
Periodic Maintenance
Chart .......................... 101
Physical Control of the
ATV .............................. 23
Pre-Ride Check ................ 59
Pre-Ride Inspection........... 80
Protective Apparel............. 20
199
R
Registration, Warranty ..... 178
Rider Comfort .................. 38
Riding Rules .................... 61
S
Safe Operation Practices .... 82
Safe Riding Gear .............. 36
Safety Labels and
Locations....................... 39
Safety Training ................. 33
Safety Warnings ............... 17
Severe Use Definition ...... 102
Shift Lever....................... 69
Shock Spring
Adjustment................... 134
Skidding or Sliding ............ 30
Spark Arrester................ 124
Spark Plug .....................119
Sportsman 110
Specifications ............... 162
Stalling While Climbing a
Hill ............................... 26
Starting the Engine............ 84
Steering Inspection ......... 134
Stopping the Engine .......... 85
Storage......................... 152
T
Throttle Controls ............... 67
Throttle System .............. 126
Tires ............................ 142
Toe Alignment ................ 133
Trademarks ....................... 3
Transmission (Main
Gearcase).....................116
Transporting the ATV ....... 155
Turning Around on a Hill ..... 90
U
Using Alcohol or Drugs....... 21
V
Vehicle Break-in Period ...... 77
Vehicle Identification
Numbers ....................... 13
Vehicle Immersion............118
200
WARNING
Improper vehicle use can result in
SEVERE INJURY or DEATH.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
S without proper training or instruction
S at speeds too fast for your skills or the conditions
S on public roads - a collision can occur with
another vehicle
S with a passenger - passengers affect balance
and steering and increase risk of losing control
ALWAYS:
S use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns
S avoid paved surfaces - pavement may
seriously affect handling and control
For your nearest Polaris dealer, call 1-800-POLARIS (765-2747)
or visit www.polaris.com
Polaris Industries Inc.
2100 Highway 55
Medina, MN 55340
Part No. 9929071 Rev 01
Printed in Taiwan
Pantone 419C
